Battery Structure and Protector

ABSTRACT

The present disclosure relates to a battery structure for an electric vehicle. The battery structure comprises a battery case for at least one battery module and a protector interconnected to the battery case including a top belt, a bottom belt and a core arranged between and interconnecting the top belt and the bottom belt.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation application that claims the benefit of the filingdate of U.S. Continuation application Ser. No. 17/315,602, filed on May10, 2021, that claims priority to U.S. National Stage Application No.16/486,387, filed on Aug. 15, 2019, that claims priority tointernational PCT Application No. PCT/EP2018/053354, filed on Feb. 9,2018, that in turn claims priority to Swiss Patent Application No. CH00186/17, filed on Feb. 17, 2017, which are each hereby incorporated byreference in their entirety.

FIELD OF THE INVENTION

The present disclosure relates to a battery structure for an electricvehicle and a is protector for a battery pack.

BACKGROUND OF THE INVENTION

DE102015101096A1 was first published in July 2016 in the name of PorscheAG. It relates to a battery structure. The battery facilities include anunderbody battery between a bottom plate and a floor. At least onedeformation zone is foreseen to avoid unwanted damage to a battery ofthe underbody. The deformation zone is below the battery facilities. Thebottom plate can deform upwards.

W015077000A1 was first published in May 2015 in the name of Atieva Inc.It relates to a battery pack protection system for use with an electricvehicle in which the battery pack is mounted under the car. The systemutilizes a plurality of deformable cooling conduits located between thelower surface of each of the batteries and the lower battery packenclosure panel. A thermal insulator is interposed between the conduitsand the lower enclosure panel. A layer of thermally conductive materialmay be included which is interposed between the cooling conduits and thethermal insulator and in contact with a lower surface of each of thecooling conduits.

The cooling conduits are configured to deform and absorb impact energywhen an object, such as road debris, strikes the lower surface of thelower battery pack enclosure panel. Further protection may be achievedby positioning a ballistic shield, alone or with a layer of compressiblematerial, under the bottom surface of the battery pack.

FR2977554A was first published in January 2013 in the name of FiorConcept. It relates to a vehicle having a frame which comprises ahoneycomb shaped structure that forms a plate. A surface of an upperplate is rigidly connected to an upper surface of the plate. A surfaceof a bottom plate is rigidly connected to a lower surface of the plate.Resistant structures are protruded above a wheel notch and attached withthe notch by a complete and rigid connection. An external resistant beltis attached with an external circumference of the plate by the completeand rigid connection and placed partially between the structures ofpassages of the wheels.

SUMMARY OF THE INVENTION

From the prior art, parts for the protection of battery packs arrangedin the vehicle floor are known which often absorb the occurring energyby plastic deformation over a relatively large deformation path. Theprotectors known from the prior art are either made from metal orcomposite material and are not appropriate for absorbing high punctualimpact loads.

One disadvantage of the systems known from the prior art is that asignificant amount of space between the underride protection and theparts to be protected is consumed as the structure used to fulfill therequirements, i.e. depleting of the introduced energy withoutsignificant introduction of forces into the parts to be protected.Depending on the type of vehicle this can have a significant impact onat least one of the following parameters: Ground clearance, accessheight, head clearance, vehicle height, cross-sectional area.

Therefore, it is an object of the present disclosure to provide animproved protector for a battery structure which offers betterperformance for protecting of a battery structure in an underfloor of anelectric vehicle, namely high local stress, e.g. due to impact by animmersible traffic bollard. It is a further object to provide aprotector which is lighter and needs less space in height direction todeplete the occurring energy by elastic and/or plastic deformation.

The protector according to the present disclosure helps to preventdamage of at least one battery module arranged in an underfloor of anelectric car. The protector normally comprises a top belt and a bottombelt and a there between arranged core interconnecting the top belt andthe bottom belt. The top belt preferably has a waveform in at least onedirection. Depending on the field of application, the waveform mayextend in two directions arching from one beam to another beameffectively receiving and distributing high local load as describedhereinafter in more detail. The protector according to the presentdisclosure offers optimized distribution of the occurring energy intothe structure by a combination of elastic and/or plastic deformation.The top belt and the bottom belt, as well as the there-between arrangedcore, are preferably made from at least one out of the following groupof materials: Aluminum, steel, fiber reinforced composite material,thermoplastic material.

In a preferred variation the top belt is made from aluminum and/or steeland/or thermoplastic material comprising short fibers, while the bottombelt is preferably made from fiber reinforced composite materialcomprising continuous fibers. The core is preferably made from honeycomband/or foam. Depending on the field of application, other combinationscan be used.

A preferred selection of parameters to optimize the structure are: Shapeof the cross-section of the wave, shape (curvature) of the wave, corematerial, chamber height, wall thickness, belt material.

In a preferred variation the battery structure for an electric vehiclecomprises a battery case encompassing at least one battery module and aprotector. The protector comprises a top belt and a bottom belt and acore arranged between and interconnecting the top belt and the bottombelt. The top belt preferably has a wavelike cross-section extending inat least one direction. The wavelike cross-section of the top belt mayextend in longitudinal and/or transverse direction of the electricvehicle resulting in a wavelike top belt, wherein the waves extend inone and/or two directions simultaneously. The waves can be regular orirregular. The waves of the top belt can extend in two directions ifappropriate.

The protector is preferably interconnected to at least longitudinaland/or at least one transverse beam of the battery case. In a variationthe longitudinal and the transverse beams are arranged grid-like. Thetop belt can be interconnected to a frame of the battery case. Theprotector is preferably arranged below a lower sled wall of the batterycase housing with the at least one battery module inside. One aim isthat the risk that an impacting object can reach the lower sled wall issignificantly reduced.

The top belt comprises, with respect to the core, elevations (thickerareas of core) and thereto alternating depressions (thinner area ofcore) arranged in a wavelike structure. The depressions and elevationsspan across the beams, respectively the frame of the battery case, in anarch-like manner resulting in a very efficient structure, especially inthe case of punctual loads occurring from the outside (opposite side ofthe protector). The top belt in the area of at least one depression canbe directly interconnected to the bottom belt. The top belt in the areaof at least one depression can be directly connected to the bottom belt.Alternatively or in addition, the top belt can be in the area of atleast one depression indirectly connected to the bottom belt, e.g. via asection of the same or a different core. Good results can be achieved ifthe core is a honeycomb, e.g. made from aluminum, steel or injectionmolded thermoplastic material, and/or a foam. The bottom belt preferablyhas a primarily flat structure, especially in the case that it providesthe outer layer of the underfloor. Stiffening corrugations may beapplied if necessary as part of the structure and/or as separateelements. The core can be made from an isolating material. Ifappropriate at least one of the depressions can be used for conveying ofa fluid for cooling and/or heating of the at least one battery module.

It is to be understood that both the foregoing general description andthe following detailed description present embodiments, and are intendedto provide an overview or framework for understanding the nature andcharacter of the disclosure. The accompanying drawings are included toprovide a further understanding, and are incorporated into andconstitute a part of this specification. The drawings illustrate variousembodiments, and together with the description serve to explain theprinciples and operation of the concepts disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

The herein described invention will be more fully understood from thedetailed description given herein below and the accompanying drawingswhich should not be considered limiting to the invention described inthe appended claims. The drawings are showing:

FIG. 1 a battery structure according to the present disclosure;

FIG. 2 a longitudinal and a transverse section view across a batterycase according to the present disclosure;

FIG. 3 a first and a second embodiment of a protector in a first and ina second section view;

FIG. 4 a third embodiment of a protector.

DESCRIPTION OF THE EMBODIMENTS

Reference will now be made in detail to certain embodiments, examples ofwhich are illustrated in the accompanying drawings, in which some, butnot all features are shown. Indeed, embodiments disclosed herein may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Whenever possible, like reference numbers will be used torefer to like components or parts.

FIG. 1 shows a battery structure 1 in an exploded view from below. FIGS.2 a and 2 b schematically show an impact of an object 14 into a batterystructure 1 from below. FIG. 3 a through 3 d show cross-section views ofa first and a second variation of a protector 4 from the side alongsection line A-A. FIG. 4 shows a third variation of a protector 4 in aperspective view.

As shown in FIG. 1 , the battery structure 1 comprises a battery case 2for at least one battery module 3 and a protector 4. The elements areshown in a disassembled, exploded manner. The assembly is schematicallyindicated by dotted lines. As shown for example in FIGS. 2 a and FIG. 3, the protector 4 comprises a top belt 5 and a bottom belt 6 and a core7 arranged between and interconnecting the top belt 5 and the bottombelt 6 at least in certain areas. In the shown variation, the core is ahoneycomb, wherein the cells of the honeycomb extend in a verticaldirection (i.e., z-direction). As schematically indicated in FIG. 1 theprotector 4, namely the top belt 5, can be interconnected to a frame 10of the battery case 2.

As shown in FIG. 2 a , the top belt 5 of the illustrated variation has awavelike cross-section. The top belts 5 are interconnected tolongitudinal beams 8 of the battery case 2. The top belt 5 compriseselevations 11 and thereto alternating depressions 12 forming waves 13,which are arranged in a regular manner. The waves 13 are here extendingin the x-direction only. Other arrangements are possible.

In the variation as shown in FIG. 2 a , respectively the section viewaccording to FIG. 3 a , the top belt 5 in the area of the depressions 12is directly interconnected to the bottom belt 6, which has an inprinciple flat design. As shown in the section view according to FIG. 3c , the top belt 5 can be alternatively or in addition in the area thedepressions 1 2 indirectly connected to the bottom belt 6 via the core7.

FIG. 3 b shows a section view along section line A-A according to FIG. 3a , and FIG. 3 d shows a section view along section line A-A accordingto FIG. 3 c.

For better temperature control of the at least one battery module, thecore 7 can be made from an isolating material such as foam. Ifappropriate at least one of the depressions 12 is used for conveying ofa fluid for cooling and/or heating of the at least one battery module.

FIG. 4 shows a further variation of a protector 4 in a perspective viewfrom above. The top belt 5 has a wave-structure extending in twodirections (x, y) simultaneously. The bottom belt 6 (not shown indetail) has a flat design. Depending on the field of application, otherpossibilities exist. In an area where the longitudinal and thetransverse beams 8, 9 connect (indicated by dashed lines) the top belt 5has a flat design. Compared to the prior art, the dome-like depressions12 offer very high stiffness and energy consumption capabilityespecially in the case of punctual impact loads from below 8 (i.e.,z-direction).

The words used in the specification are words of description rather thanlimitation, and it is understood that various changes may be madewithout departing from the spirit and scope of the invention.

1. A battery structure for an electric vehicle comprising a. a batterycase for at least one battery module and b. a protector interconnectedto the battery case comprising i. a top belt ii. a bottom belt and iii.a core arranged between and interconnecting the top belt and the bottombelt.
 2. The battery structure according to claim 1, wherein theprotector is configured to be disassembled from the battery case.
 3. Thebattery structure according to claim 1, wherein the protector isinterconnected to a frame of the battery case.
 4. The battery structureaccording to claim 3, wherein the battery case comprises a plurality oflongitudinal beams and transverse beams, which are arranged grid-like,thereby providing a plurality of slots for a plurality of batterymodules.
 5. The battery structure according to claim 4, wherein thebattery case comprises an outer frame surrounding and interconnected tothe plurality of longitudinal beams and transverse beams therebyenclosing the plurality of slots for the battery modules.
 6. The batterystructure according to claim 5, wherein an outer periphery of theprotector is interconnected to the outer frame of the battery case. 7.The battery structure according to claim 5, wherein the outer frame ofthe battery case comprises a plurality of holes each configured toreceive a connector to connect the battery structure to the electricvehicle.
 8. The battery structure according to claim 4, wherein the topbelt is interconnected to at least one of a longitudinal beam and atransverse beam of the battery case.
 9. The battery structure accordingto claim 1, wherein the core is at least one of a honeycomb and a foam.10. The battery structure according to claim 1, wherein the core is madefrom an isolating material.
 11. The battery structure according to claim1, wherein at least one of the top belt, the bottom belt, and the corecomprise at least one of aluminum, steel, fiber reinforced compositematerial, and thermoplastic material.
 12. The battery structureaccording to claim 1, wherein the top belt is made from at least one ofaluminum, steel and thermoplastic material comprising short fibers, andwherein the bottom belt is made from fiber reinforced composite materialcomprising continuous fibers.
 13. The battery structure according toclaim 1, wherein the bottom belt has a primarily flat structure.
 14. Thebattery structure according to claim 1, wherein the bottom beltcomprises stiffening corrugations, which form part of the structure ofthe bottom belt or which are applied as separate elements.
 15. Thebattery structure according to claim 1, wherein the protector isarranged below a lower sled wall of the battery case housing the atleast one battery module inside.
 16. The battery structure according toclaim 14, wherein the bottom belt provides an outer layer of anunderfloor.
 17. The battery structure, according to claim 1, wherein thetop belt comprises elevations and alternating depressions arranged in awavelike structure.
 18. The battery structure according to claim 17,wherein at least one of the depressions is used for conveying of a fluidfor cooling and/or heating of the at least one battery module.
 19. Aprotector for the battery structure according to claim 1.